Recently, the engine calibration technique has been much more complicated than that of the past engine case in order to satisfy the strict emission regulations. The current calibration method for the diesel engine which has an increasing market is both costly and time-consuming. New engine calibration method is required to develop for high-quality diesel engines with low cost and release it at the appropriate time. This study provides the optimal calibrating technique for complex engine systems using statistical modeling and numerical optimization. Firstly, it design a test plan based on Design of Experiments, a V-optimality methodology which is suitable looking for set-points, and determine the shape of test engine response. Secondly, it uses functions to make linear regression model for data analysis and optimization to fit the models of engines behavior. Finally, it generates the optimal calibrations obtained directly from empirical engine models using Grey Relational Analysis and compares the calibrations with data. This method can develop a process for systematically identifying the optimal balance of engine emissions.